Coating Technology for Flexible Packaging

Lee A. Ostness

Product Manager - Coating & Drying Systems

Flexible Packaging is widely used in todays world. It is used to package
a multitude of products such as: processed meat, processed cheese,

fresh red meat, bulk liquids, cereals, cake mix, coffee, medical device
films, snacks and many others.

There are many different substrates and

coatings used to create these packages to produce the various levels of

barrier protection.
SUBSTRATES

see chart
COATINGS

PET

1 10 mil

Primers

0.04 0.4 gsm

PE

1 8 mil

Adhesives

3.25 6.5 gsm

Al Foil

20 60

PVDC

1.6 6.5 gsm

BOPP/OPP

0.4 2 mil

Wash-coats

0.8 1.5 gsm

CPP

1 4 mil

PVOH

0.5 gsm

Nylon

0.4 2 mil

Lacquers

5.0 gsm

MetPET

1 10 mil

Varnishes

0.02 0.04 gsm

Cellophane

0.8 1 mil

Acrylic Polyurethanes

0.3 gsm

A typical package may be constructed of several layers of substrates and

coatings. Two typical constructions are illustrated below.

The beverage

package is constructed with PET/Printed/Primer coating/LDPE/Foil/LDPE(heatseal).

The Retort Package is a different construction requiring two coatings,
PET/Printed/Adhesive coating/Foil/Primer coating/LDPE.

The foil is a barrier

layer and may be substituted with Metalized PET, Nylon, or EVOH

depending on the amount or type of barrier required. see illustration
PET

12.6

(PRINT)

PET

12.6

(PRINT)

PRIMER

0.04

ADHESIVE 3.25 6.5

LDPE

12.6

FOIL

FOIL

6.3

LDPE (Heat Seal) 25

Beverage Package

PRIMER
LDPE

6.3
0.04
25

Retort Package

The constructions incorporate the use of solution coating(s) to enhance

either the barrier and/or the adhesion properties. The focus of this paper
is to discuss how these coatings are applied.
A solution coating is a liquid with solids dispersed in the liquid to assist
the wetting of the substrate it is applied to.

The

liquid can be a combination of solvents or water

determined by its ability to maintain the dispersion
of the solids. The solution coating is applied to a

continuous web with a Coater and then passed

through a Dryer to remove the liquid leaving a thin

layer of solids on the substrate. The coater will be

either a gravure type or a smooth roll type.

The

dryers are normally a roll support design or a

floatation design. The roll support dryer consist of
rolls supporting the web with opposing impingement nozzles drying the
web. The floatation dryer consist of nozzles on both sides of the web
creating a sign wave affect to float the web.
Coating heads have a variety of applications, strengths and weaknesses.
How do you objectively select the right coating head? There are 50 plus
coater configurations available to apply an infinite number of coating
solutions.

To select the coater for your needs you first need to know

your coating and substrates properties, then match these properties with
the coaters abilities/limitations.
Coating

Substrate

Coater

% Solids

Absorbency

Speed Range

Viscosity

Surface Tension

Coat Weight Range

pH

Tear Strength

Solids Range

Shear Stability

Smoothness

Viscosity Range

Density

Caliper

Appearance

Solvent/Water Based

Melt Point

There are four main coater configurations used in the Flex Package

construction. The four types are Direct Gravure, Reverse Gravure, Offset
Gravure and Smooth Roll.

The

gravure coaters utilize steel rolls

with patterns engraved into the

face of the roll.

This pattern

determines how much coating is

Direct
Gravure

Reverse
Gravure

Offset
Gravure

Smooth
Roll

carried to the web. The coating is

applied to the gravure, metered off the surface, leaving coating only in
the engraved pattern, then transferred to the web that is supported by
the rubber covered back-up roll.

The smooth roll coater applies the

coating from an open pan, picking up the coating with a smooth steel roll
partially immersed into the pan, then the web is pressed against the steel
roll with the rubber covered back-up roll. The speed of the steel roll and
amount of pressure against the steel roll combine to control the amount
of coating applied to the web.
The gravure roll is a steel roll with a precise pattern engraved into the
surface of the roll. There are several gravure vendors, each with their
own names for these patterns. The picture shows one vendors patterns
and the names associated
with them. The patterns
are called from left to

right; Tri-Helical, Pyramid, Quadrangular, and Hexagonal.

The amount

of coating in each cell (pattern) is measured and referred to as Billion

Cubic Microns (BCM).

To select the correct gravure pattern for your

application, you need to reference a coat weight chart provided by most

gravure vendors. On this chart locate your coat weight under the percent

solids column that matches your formulation. Then follow the row to the
left and it determines the volume required to deliver the desired coating
to the substrate.

This chart is setup for the Direct Gravure method. The Reverse Gravure
method will need to add approximately 20% to the desired coat weight
and for Offset Gravure method add approximately 75%.

This will be

explained as we discuss each type of coater and their operating

parameters.

The chart is only a starting point to get you close to your target. A large
amount of the time the gravure pattern will need to be adjusted to
achieve the correct coat weight due to the different coating and/or
substrate characteristics.
Direct Gravure Coater:
The Direct Gravure Coater consists of a rubber
covered back-up roll, a gravure roll, and a coating
applicator. The back-up roll is covered with a rubber

compound and is used to transport the web through

the coating process.

The back-up roll is pressed

against the gravure roll creating a slight nip which pulls the coating out
of the gravure cells and deposits the coating onto the web. The gravure
roll is a steel roll with a pattern engraved into the face of the roll. These
cells are filled with the coating and doctored of the surface of the roll

leaving a precise amount of coating on the gravure roll. The roll then

transports the coating to the nip where it is transferred to the web. The
coating applicator is either an enclosed chamber with two doctor blades
or an open pan with a doctor blade assembly to remove the excess
coating.

In the Direct Gravure mode the gravure roll and

GSM

the web are moving in the same direction at the point of

contact. The speed of the gravure roll is usually the same

as the web but it may be adjusted to 10% of the web

95%

100%

105%

Gravure Speed

speed.

The coat weight is determined by the gravure

volume and the coating solids.

Reverse Gravure Coater:

The Reverse Gravure Coater consists of the same
equipment as the Direct Gravure coater.

In this

method the gravure roll runs in the opposite

direction to the web and varies in speed from 50%
to 150% of web speed.

The most common

operating speed is 110% to 120%. The coat weight

in this mode when plotted will create a bell shaped curved by running the
gravure roll from 50 to 150% of web speed measuring the coat weight
every 10%. If the same gravure pattern from the Direct gravure is used
the highest coat weight will only be about 80% of the direct
GSM

gravure methods.

The coat weight is determined by the

gravure pattern, the coating solids, and by the speed of the

gravure roll. This method will lay the coating down with a
smoother appearance because of the shearing action

Gravure Speed created at the nip.

50%

100%

150%

The appearance created by the direct

gravure method is a rougher texture because at matched speeds and in

the same direction you are virtually printing the pattern onto the web.

Offset Gravure Coater:

The Offset Gravure Coater consist of a steel back-up

roll, a rubber covered applicator roll, a gravure roll,
and a coating applicator. The back-up roll is chrome

plated steel roll used to transport the web through

the coating process and create the nip between the
web and the applicator roll. The Applicator roll is a
rubber covered roll used to transfer the coating from
the gravure roll to applicator roll, to the web. The gravure roll is a steel
roll with a pattern engraved into its surface. The coating applicator is
either an enclosed chamber with two doctor blades to an open pan with a
doctor blade assembly to remove the excess coating. In this method all
the rolls are turning in the same direction at the point of contact at each
nip. The back-up roll is operating at line speed, the applicator roll most
usually is operating at 98% of line speed (5%), and the gravure roll
operates at 25 to 35% of line speed. With this method
GSM

the coat weight curve when plotted would be a steady

incline then level off to a fairly straight plain. The curve
would be generated by varying the speed of the gravure
10%

60%

100%

roll from 5% to 100 % in increments of 5%.

The coat

Gravure Speed weight usually levels off when the gravure roll reaches

about the 60% of line speed.

The shearing action created by the

differential speeds and the two nip points generally apply a smooth
coating.

Smooth Roll Coater:

The Smooth Roll Coater consist of a rubber covered backup roll, a steel chrome plated pick-up roll, sling guards
and a coating pan.

The back-up roll is covered with a

rubber compound and is used to transport the web

through the coating process. The back-up roll is pressed
against the pick-up roll creating a slight nip.

The pick-up roll is

immersed into the coating pan and transports the coating to the nip
between the web and the pick-up roll. The coating is applied to the web

at this nip point. The amount of coating applied is dependent on the

hydraulic forces at the coater nip created by the speed of the pick-up roll

and the nip force. The coating pan is filled with a solution coating and in
most cases it has an overflow weir so the coating may be recirculated.

The rubber compound selected has to consider several operational

conditions. The parameters consist of the durometer, surface tension,
resilience, tear resistance.

The durometer needs to be based on the

speed of the machine line and the viscosity of the coating.

With this

method the coat weight increases with higher speed and higher viscosity.
The surface tension is selected based on the compound of the rubber.
This method requires the rubber to repel the coating, so only the web will
be coated. The resilience and tear strength are required due to the high
forces and different web widths. The coat weight is determined by the nip
width and the pick-up roll speed and the curve will be a line

with a slow incline and then when the hydraulic forces

GSM

overcome the nip the line transitions into a steep incline.

The wider the nip the lower on the graph the curve is

10%

100%

Pick-up Speed

generated.

The gravure coater requires the rubber

rolls to be undercut slightly narrower than
the web width whereas in the smooth roll

method the rubber rolls are full width.

When the coating is transferred to the

web or applicator roll from the gravure cells it only needs to be

transferred at the width of the web. If the rubber is not undercut the
coating would form a flooded nip outside the area of the web and
gradually move into the web area, creating a hydraulic force that would
increase the coat weight to unacceptable levels in these areas.

If the

rubber was undercut, the area outside the width of the web would
continue to travel around and back into the coating applicator.

The

smooth roll coater requires a full width rubber roll to create the flooded
nip. If the nip was not flooded across the entire web, some areas would

have either too little coating or none at all. This flooded nip also requires

sling guards at the end of the rolls to catch and return into the pan any of
the slinging coating.
A nip is required between the coating rolls in all of the methods listed
above. What is a nip? A nip is the amount of contact that is generated
between the rolls when they are pressed together. The softer the rubber
durometer, the wider the nip will be with the same pressure.

As the

pressure increases the nip width increases. How do you measure the nip
width?

There are several methods available using

carbon nip paper, aluminum foil, liquid coating and

IMPRESSION
PAPER
RUBBER
COVERED
ROLL

piece of paper, a computerized nip blanket. What all

these methods have in common is you must place

TORQUE SHAFT
SHOULD BE
LEVELED

something between the two rolls before you close

them together.

In review, the coat weight control of each coater as depicted in the charts
show that the only coater that cannot adjust coat weight is the Direct
Gravure (shown as forward gravure in the illustration).
Reverse
Gravure

Forward
Gravure

Offset
Gravure

Smooth
Transfer

100%

150%

GSM

50%

Gravure Speed

GSM

GSM

GSM

95%

100%

105%

Gravure Speed

10%

60%

100%

Gravure Speed

10%

100%

Pick-up Speed

The smooth roll coater can control coat weight until the hydraulic force
over comes the coater nip and then the coat weight climbs dramatically.

The Gravure coaters offer excellent coat weight control and are stable

through out all line speeds but require an undercut rubber roll for each
web width. A sleeve system may be used in the rubber roll location. The

sleeve system allows the rubber undercut sleeve to be changed in less

than 15 minutes. This system still requires a sleeve for each web width.
The smooth roll coater offers coat weight control but needs adjustment

going from low to high line speeds. This is referred to as unstable, as

the line speed increases so does the amount of coating supplied. The

result is much of the coated web during speed-up and slow down is
waste. The advantage to the smooth roll coater is it only requires one
rubber roll for all web widths.
Gravure
GSM

Smooth Roll

Line Speed

The Direct Gravure coater is used primarily on substrates that are fragile,
like metalized PET or printed webs. If the roll applying the coating to
these two examples were operated in the reverse direction or at a
differential speed, then that roll could damage the print layer or pick off
the foil. Operating the roll in the forward direction with matched speeds
will apply the coating without damage. The smooth roll coater can adjust
coat weights and apply coatings without damage to the layers. The limit
on this coater is the flooded nip. This application works well on films or
coated papers, BUT on open face paper the coat weight cannot be
controlled. Passing the open faced paper through the flooded nip will
saturate the web and apply excessive coating.
Take all the parameters from this paper and create a chart, now you can
select the correct coater for your process.
Direct

Reverse

Offset

Smooth

Gravure

Gravure

Gravure

Roll

Ability to Adjust Coat Weight

No

Yes

Yes

Yes

Ability to Coat Paper

Yes

Yes

Yes

No

Ability to Coat Film

Yes

Yes

Yes

Yes

Stable at all Line Speeds

Yes

Yes

Yes

No

Requires Under Cut Rubber Roll

Yes

Yes

Yes

No

Ability to Coat Printed Film

Yes

No

Yes

Yes

Ability to Coat Foil

Yes

No

Yes

Yes

Coater Selection

2006 PLACE
Conference
September 17-21
Cincinnati, Ohio

Coating Technology
for Flexible Packaging
Presented by:

Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery

Typical Products
Product
Processed Meat
Processed Cheese
Fresh Red Meat
Bulk Liquids
Cereal/Cake Mix
Medical Devices Films
Coffee
Fresh Produce
Snacks

Package Type
Pouches, Vacuum Packages
Pouches, Wraps
Barrier, Shrink Bags
Pouches, Bag in Box
Inner Liners
Pouches, Thermal Formed
Brick Packs, Pouches
Breathable Bags
Bags

Flex-Pack Components
Substrates
PET
PE
Al foil
BOPP/OPP
CPP
Nylon
METPET
Cellophane

Coatings
1-10 mil
1-8 mil
20-60
0.4-2 mil
1-4 mil
0.4-2 mil
1-10 mil
0.8-1 mil

Primers
0.04-0.4 gsm
Adhesives
3.25-6.5 gsm
PVDC
1.6-6.5 gsm
Wash-coats
0.8-1.5 gsm
PVOH
0.5 gsm
Lacquer
5.0 gsm
Acrylic Polyurethane
0.3 gsm
Varnish
0.02 0.04 gsm

Typical Product Structures

PET

12.6

(PRINT)

PET

12.6

(PRINT)

PRIMER

0.04

ADHESIVE 3.25 6.5

LDPE

12.6

FOIL

FOIL

6.3

LDPE (Heat Seal) 25

Beverage Package

PRIMER
LDPE

6.3
0.04
25

Retort Package

Note: The foil is a barrier layer and may be substituted with METPET, Nylon, or EVOH
depending on the amount or type of barrier layer needed.

COATER/DRYER
Coater
Smooth roll
Backing Roll not Undercut
Pan Fed

Direct Gravure
Backing Roll Undercut
Sleeve
Pan Fed
Enclosed Applicator

Dryer
Air Floatation Nozzles
Roll Support

FLEX-PACK COATERS

Direct
Gravure

Reverse
Gravure

Offset
Gravure

Smooth
Roll

Methodology of Application

Gravure Coater

Smooth Roll Coater

Gravure Engraved Patterns

Volume
BCM
Billion Cubic Microns
The formula is based on
ink technology. Many of
today's coatings are of
an unique composition.
Use this formula for a
better understanding of
how the cell volumes are
achieved. Coat weights
may vary when different
coatings are applied with
the same cell volume.

formula from Consolidated Engravers

DIRECT GRAVURE: is 80 % of what the chart displays

REVERSE GRAVURE: is generally 80% of Direct Gravure
DIFFERENTIAL OFFSET GRAVURE: is generally 25% of Direct Gravure

ENGRAVING COATING CHART

WEIGHT IN POUNDS DRY SOLIDS PER REAM - 432,000 SQUARE INCHES
WEIGHT OF MATERIAL 8 LBS. PER GALLON IN SOLUTION
CHART #1
NUMBER
200
180
165
150
142
132
120
116
108
100
90
80
70
65
60
55
50
45
40

CELL
DEPTH
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104

VOLUME
2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0

DIRECT FORWARD GRAVURE

CHART #4
CELL
VOLUME
DEPTH

PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.21
0.26
0.23
0.29
0.26
0.32
0.51
0.64
0.56
0.70
0.64
0.80
0.77
0.96
0.81
1.02
0.85
1.06
1.03
1.20
0.98
1.22
1.02
1.28
1.15
1.44
1.28
1.60
1.49
1.86
1.58
1.98
1.94
2.42
2.30
2.88
2.67
3.33

CHART #2
25%
SOLIDS
0.32
0.36
0.40
0.80
0.88
1.00
1.20
1.28
1.32
1.40
1.52
1.60
1.80
2.00
2.32
2.48
3.02
3.60
4.16

35%
SOLIDS
0.47
0.53
0.59
1.18
1.30
1.48
1.78
1.89
1.95
2.07
2.25
2.37
2.66
2.96
3.43
3.67
4.47
5.33
6.15

45%
SOLIDS
0.70
0.79
0.88
1.75
1.92
2.19
2.63
2.80
2.89
3.07
3.33
3.50
3.94
4.38
5.08
5.43
6.61
7.88
9.11

PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.17
0.21
0.19
0.23
0.20
0.26
0.41
0.51
0.45
0.56
0.51
0.64
0.61
0.77
0.65
0.82
0.68
0.85
0.82
0.96
0.78
0.98
0.82
1.02
0.92
1.15
1.02
1.28
1.19
1.49
1.26
1.58
1.55
1.94
1.84
2.30
2.13
2.66

25%
SOLIDS
0.26
0.29
0.32
0.64
0.70
0.80
0.96
1.02
1.06
1.12
1.22
1.28
1.44
1.60
1.86
1.98
2.42
2.88
3.33

35%
SOLIDS
0.38
0.42
0.47
0.94
1.04
1.18
1.42
1.51
1.56
1.66
1.80
1.90
2.13
2.37
2.74
2.94
3.58
4.26
4.92

45%
SOLIDS
0.56
0.63
0.70
1.40
1.54
1.75
2.10
2.24
2.31
2.46
2.66
2.80
3.15
3.50
4.06
4.34
5.29
6.30
7.29

PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.14
0.17
0.15
0.19
0.16
0.20
0.33
0.41
0.36
0.45
0.41
0.51
0.49
0.61
0.52
0.65
0.54
0.68
0.66
0.77
0.63
0.78
0.66
0.82
0.74
0.92
0.82
1.02
0.95
1.19
1.01
1.27
1.24
1.55
1.47
1.84
1.71
2.13

25%
SOLIDS
0.20
0.23
0.26
0.51
0.56
0.64
0.77
0.82
0.84
0.90
0.97
1.02
1.15
1.28
1.48
1.59
1.93
2.30
2.66

35%
SOLIDS
0.30
0.34
0.38
0.76
0.83
0.95
1.14
1.21
1.25
1.32
1.44
1.52
1.70
1.89
2.20
2.35
2.86
3.41
3.94

45%
SOLIDS
0.45
0.51
0.56
1.12
1.23
1.40
1.68
1.79
1.85
1.96
2.13
2.24
2.52
2.80
3.25
3.48
4.23
5.04
5.83

OFFSET GRAVURE
CHART #12
PYRAMID CELL
CELL
15%
5%
VOLUME
DEPTH
SOLIDS SOLIDS
0.0008
2.6
0.06
0.07
0.0009
3.2
0.06
0.08
0.0010
3.4
0.07
0.08
0.0020
7.5
0.14
0.17
0.0022
8.2
0.15
0.18
0.0025
9.7
0.17
0.21
0.0030
11.0
0.20
0.25
0.0032
11.9
0.21
0.27
0.0033
12.2
0.22
0.28
0.0035
13.9
0.27
0.32
0.0038
16.0
0.26
0.32
0.0040
17.3
0.27
0.34
0.0045
18.0
0.30
0.38
0.0050
20.4
0.34
0.42
0.0058
24.4
0.39
0.49
0.0062
26.6
0.42
0.52
0.0076
33.7
0.51
0.64
0.0090
41.0
0.61
0.76
0.0104
48.0
0.70
0.88

25%
SOLIDS
0.08
0.10
0.11
0.21
0.23
0.26
0.32
0.34
0.35
0.37
0.40
0.42
0.48
0.53
0.61
0.65
0.80
0.95
1.10

35%
SOLIDS
0.12
0.14
0.16
0.31
0.34
0.39
0.47
0.50
0.51
0.55
0.59
0.63
0.70
0.78
0.91
0.97
1.18
1.41
1.62

45%
SOLIDS
0.18
0.21
0.23
0.46
0.51
0.58
0.69
0.74
0.76
0.81
0.88
0.92
1.04
1.16
1.34
1.43
1.75
2.08
2.41

0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104

2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0

DIRECT REVERSE GRAVURE

CHART #8
CELL
VOLUME
DEPTH
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104

2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0

NUMBER
200
190
180
165
150
140
130
120
110
96
85
75
65
55
45
35
30
25
16

CELL
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

VOLUME
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

DIRECT FORWARD GRAVURE

CHART #5
CELL
VOLUME
DEPTH

QUADRANGULAR CELL
15%
25%
5%
SOLIDS SOLIDS SOLIDS
0.22
0.32
0.48
0.27
0.40
0.60
0.33
0.48
0.72
0.30
0.49
0.80
0.46
0.68
1.00
0.51
0.76
1.12
0.55
0.81
1.20
0.59
0.87
1.28
0.71
1.05
1.56
0.80
1.19
1.76
0.90
1.32
1.96
0.98
1.46
2.16
1.10
1.62
2.40
1.19
1.76
2.60
1.24
1.84
2.72
1.28
1.89
2.80
1.64
2.43
3.60
2.19
3.25
4.80
3.11
4.60
6.80

CHART #3
35%
SOLIDS
0.71
0.89
1.07
1.30
1.48
1.66
1.78
1.89
2.31
2.61
2.90
3.20
3.55
3.85
4.03
4.14
5.33
7.10
10.06

45%
SOLIDS
1.05
1.31
1.58
1.93
2.19
2.45
2.63
2.80
3.42
3.85
4.29
4.73
5.26
5.69
5.96
6.13
7.88
10.51
14.89

50%
SOLIDS
1.31
1.63
1.96
2.39
2.72
3.05
3.26
3.48
4.24
4.79
5.33
5.88
6.53
7.07
7.40
7.62
9.79
13.06
16.50

35%
SOLIDS
0.57
0.71
0.86
1.04
1.18
1.33
1.42
1.51
1.85
2.09
2.32
2.56
2.84
3.08
3.22
3.31
4.26
5.68
8.05

45%
SOLIDS
0.84
1.05
1.26
1.54
1.75
1.96
2.10
2.24
2.74
3.08
3.43
3.78
4.21
4.55
4.77
4.90
6.30
8.41
11.91

50%
SOLIDS
1.05
1.30
1.57
1.91
2.18
2.44
2.61
2.78
3.39
3.83
4.26
4.70
5.22
5.66
5.92
6.10
7.83
10.45
13.20

QUADRANGULAR CELL
15%
25%
5%
SOLIDS SOLIDS SOLIDS
0.14
0.21
0.31
0.17
0.26
0.38
0.21
0.31
0.46
0.19
0.32
0.51
0.29
0.43
0.64
0.33
0.48
0.72
0.35
0.52
0.77
0.38
0.55
0.82
0.46
0.67
1.00
0.51
0.76
1.13
0.57
0.85
1.25
0.63
0.93
1.38
0.70
1.04
1.54
0.76
1.12
1.66
0.79
1.17
1.74
0.82
1.21
1.79
1.05
1.56
2.30
1.40
2.08
3.07
1.99
2.94
4.35

35%
SOLIDS
0.45
0.57
0.68
0.83
0.95
1.06
1.14
1.21
1.48
1.67
1.86
2.05
2.27
2.46
2.58
2.65
3.41
4.54
6.44

45%
SOLIDS
0.67
0.84
1.01
1.24
1.40
1.57
1.68
1.79
2.19
2.46
2.75
3.03
3.37
3.64
3.81
3.92
5.04
6.73
9.53

50%
SOLIDS
0.84
1.04
1.25
1.53
1.74
1.95
2.09
2.23
2.71
3.07
3.41
3.76
4.18
4.52
4.74
4.88
6.27
8.36
10.56

OFFSET GRAVURE
CHART #13
QUADRANGULAR CELL
CELL
15%
25%
5%
VOLUME
DEPTH
SOLIDS SOLIDS SOLIDS
0.0012
5.7
0.06
0.09
0.13
0.0015
7.5
0.07
0.11
0.16
0.0018
9.4
0.09
0.13
0.19
0.0022
10.9
0.08
0.13
0.21
0.0025
13.3
0.12
0.18
0.26
0.0028
15.0
0.13
0.20
0.30
0.0030
16.0
0.14
0.21
0.32
0.0032
17.2
0.15
0.23
0.34
0.0039
21.4
0.19
0.28
0.41
0.0044
26.3
0.21
0.31
0.46
0.0049
30.0
0.24
0.35
0.52
0.0054
32.0
0.26
0.38
0.57
0.0060
35.4
0.29
0.43
0.63
0.0065
40.4
0.31
0.46
0.69
0.0068
44.5
0.33
0.48
0.72
0.0070
46.6
0.34
0.50
0.74
0.0090
58.7
0.43
0.64
0.95
0.0120
81.0
0.58
0.86
1.27
0.0170
117.0
0.82
1.21
1.80

35%
SOLIDS
0.19
0.23
0.28
0.34
0.39
0.44
0.47
0.50
0.61
0.69
0.77
0.84
0.94
1.02
1.06
1.09
1.41
1.87
2.66

45%
SOLIDS
0.28
0.35
0.42
0.51
0.58
0.65
0.69
0.74
0.90
1.02
1.13
1.25
1.39
1.50
1.57
1.62
2.08
2.77
3.93

50%
SOLIDS
0.35
0.43
0.52
0.63
0.72
0.81
0.86
0.92
1.12
1.26
1.41
1.55
1.72
1.87
1.95
2.01
2.58
3.45
4.36

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

DIRECT REVERSE GRAVURE

CHART #9
CELL
VOLUME
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

120
110
95
90
84
79
72
64
59
54
50
45
42
36
35
33
28
26
24

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

VOLUME
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS
SOLIDS
0.64
0.95
1.40
0.73
1.08
1.60
0.94
1.39
2.05
1.03
1.52
2.25
1.14
1.69
2.50
1.18
1.75
2.58
1.32
1.95
2.88
1.50
2.22
3.28
1.61
2.39
3.53
1.76
2.60
3.85
1.91
2.83
4.18
2.14
3.17
4.68
2.19
3.25
4.80
2.64
3.91
5.78
2.80
4.09
5.98
2.81
4.16
6.15
3.22
4.77
7.05
3.81
5.63
8.33
4.09
6.05
8.95

35%
SOLIDS
2.07
2.37
3.03
3.33
3.70
3.81
4.26
4.85
5.22
5.70
6.18
6.92
7.10
8.55
8.74
9.10
10.43
12.32
13.24

45%
SOLIDS
3.07
3.51
4.49
4.93
5.48
5.64
6.30
7.18
7.73
8.44
9.15
10.25
10.52
12.66
13.10
13.48
15.45
18.25
19.62

50%
SOLIDS
3.80
4.35
5.57
6.11
6.79
6.99
7.81
8.89
9.57
10.46
11.34
12.70
13.04
15.68
16.23
16.70
19.15
22.61
24.31

DIRECT FORWARD GRAVURE

CHART #6

QUADRANGULAR CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.18
0.26
0.38
0.22
0.32
0.48
0.26
0.39
0.58
0.24
0.39
0.64
0.37
0.54
0.80
0.41
0.60
0.90
0.44
0.65
0.96
0.47
0.69
1.02
0.57
0.84
1.25
0.64
0.95
1.41
0.72
1.06
1.57
0.79
1.17
1.73
0.88
1.30
1.92
0.95
1.40
2.08
0.99
1.47
2.18
1.02
1.51
2.24
1.31
1.95
2.88
1.76
2.60
3.84
2.49
3.68
5.44

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

NUMBER CELL DEPTH

CELL DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
VOLUME
SOLIDS
SOLIDS
SOLIDS
SOLIDS
5.7
0.20
0.30
0.44
0.65
7.5
0.25
0.37
0.55
0.82
9.4
0.30
0.45
0.66
0.98
10.9
0.28
0.45
0.74
1.20
13.3
0.42
0.62
0.92
1.36
15.0
0.47
0.70
1.03
1.53
16.0
0.50
0.74
1.10
1.64
17.2
0.54
0.80
1.18
1.74
21.4
0.65
0.97
1.44
2.13
26.3
0.74
1.09
1.62
2.40
30.0
0.82
1.22
1.80
2.67
32.0
0.91
1.34
1.99
2.94
35.4
1.01
1.49
2.21
3.27
40.4
1.09
1.62
2.39
3.54
44.5
1.14
1.69
2.50
3.71
46.6
1.18
1.74
2.58
3.81
58.7
1.51
2.24
3.31
4.90
81.0
2.02
2.99
4.42
6.53
117.0
2.86
4.23
6.26
9.26

DIRECT REVERSE GRAVURE

CHART #10

50%
SOLIDS
1.21
1.50
1.80
2.20
2.50
2.81
3.00
3.20
3.90
4.41
4.90
5.41
6.01
6.50
6.81
7.01
9.01
12.02
15.18

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
SOLIDS
SOLIDS
SOLIDS
SOLIDS
0.16
0.24
0.35
0.52
0.20
0.30
0.44
0.66
0.24
0.36
0.53
0.79
0.22
0.36
0.59
0.96
0.34
0.50
0.74
1.09
0.38
0.56
0.82
1.22
0.40
0.60
0.88
1.31
0.43
0.64
0.94
1.39
0.52
0.78
1.15
1.70
0.59
0.87
1.30
1.92
0.66
0.97
1.44
2.13
0.72
1.07
1.59
2.36
0.81
1.19
1.77
2.61
0.87
1.29
1.91
2.83
0.91
1.35
2.00
2.97
0.94
1.39
2.06
3.05
1.21
1.79
2.65
3.92
1.61
2.39
3.53
5.23
2.29
3.38
5.00
7.40

45%
SOLIDS
0.77
0.96
1.16
1.42
1.61
1.80
1.94
2.06
2.52
2.83
3.16
3.48
3.87
4.19
4.39
4.51
5.80
7.74
10.96

50%
SOLIDS
0.96
1.20
1.44
1.76
2.00
2.24
2.40
2.56
3.12
3.53
3.92
4.33
4.81
5.20
5.45
5.61
7.21
9.61
12.14

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
SOLIDS
SOLIDS
SOLIDS
SOLIDS
0.07
0.10
0.15
0.22
0.08
0.12
0.18
0.27
0.10
0.15
0.22
0.32
0.09
0.15
0.24
0.39
0.14
0.21
0.30
0.45
0.15
0.23
0.34
0.50
0.17
0.25
0.36
0.54
0.18
0.26
0.39
0.57
0.22
0.32
0.47
0.70
0.24
0.36
0.53
0.79
0.27
0.40
0.60
0.88
0.30
0.44
0.66
0.97
0.33
0.49
0.73
1.08
0.36
0.53
0.79
1.17
0.38
0.56
0.83
1.22
0.39
0.57
0.85
1.26
0.50
0.74
1.09
1.62
0.67
0.99
1.46
2.16
0.94
1.40
2.06
3.05

45%
SOLIDS
0.32
0.40
0.48
0.59
0.66
0.74
0.80
0.85
1.04
1.17
1.30
1.44
1.60
1.73
1.81
1.86
2.39
3.19
4.52

50%
SOLIDS
0.40
0.49
0.60
0.73
0.83
0.93
0.99
1.06
1.29
1.45
1.62
1.79
1.98
2.15
2.25
2.31
2.97
3.97
5.01

VOLUME

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

OFFSET GRAVURE
CHART #14
CELL DEPTH

VOLUME

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

NOTE: THIS IS FOR CHROME PLATED GRAVURE ROLLS ONLY !

1. DETERMINE SOLIDS
2. DETERMINE TYPE OF GRAVURE COATER
3. DETERMINE TYPE OF GRAVURE CELL
4. FIND THE DESIRED COATWEIGHT IN THE CHART
5. TRACE THAT ROLL OVER TO THE VOLUME IN THE SAME CHART
6. CHOOSE THE ROLL FROM ANY VENDOR CHART THAT
MATCHES THE VOLUME AND CELL TYPE.

DIRECT FORWARD GRAVURE

CHART #7
45%
SOLIDS
0.97
1.21
1.45
1.78
2.01
2.25
2.42
2.58
3.15
3.54
3.95
4.35
4.84
5.23
5.48
5.64
7.25
9.67
13.70

CELL DEPTH

CHARTS REFERENCED FROM:

PAMARCO, INC.
ARC INDUSTRIES, INC.
AMERICAN ENGRAVING AND MACHINE CO.
MODERN ENGRAVING AND MACHINE CO.

CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

DIRECT REVERSE GRAVURE

CHART #11
CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

OFFSET GRAVURE
CHART #15
CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.51
0.76
1.12
0.58
0.86
1.28
0.75
1.11
1.64
0.82
1.22
1.80
0.91
1.35
2.00
0.95
1.40
2.06
1.05
1.56
2.30
1.20
1.77
2.62
1.29
1.91
2.82
1.41
2.08
3.08
1.53
2.26
3.34
1.71
2.53
3.74
1.76
2.60
3.84
2.11
3.13
4.62
2.24
3.27
4.78
2.25
3.33
4.92
2.58
3.81
5.64
3.05
4.51
6.66
3.27
4.84
7.16

35%
SOLIDS
1.66
1.90
2.42
2.66
2.96
3.05
3.41
3.88
4.18
4.56
4.94
5.54
5.68
6.84
6.99
7.28
8.34
9.86
10.59

45%
SOLIDS
2.46
2.81
3.59
3.94
4.38
4.51
5.04
5.74
6.18
6.75
7.32
8.20
8.42
10.13
10.48
10.78
12.36
14.60
15.70

50%
SOLIDS
3.04
3.48
4.46
4.89
5.43
5.59
6.25
7.11
7.66
8.37
9.07
10.16
10.43
12.54
12.98
13.36
15.32
18.09
19.45

TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.41
0.61
0.90
0.47
0.69
1.02
0.60
0.89
1.31
0.66
0.97
1.44
0.73
1.08
1.60
0.76
1.12
1.65
0.84
1.25
1.84
0.96
1.42
2.10
1.03
1.53
2.26
1.12
1.66
2.46
1.22
1.81
2.68
1.37
2.03
3.00
1.40
2.08
3.07
1.69
2.50
3.70
1.79
2.62
3.83
1.80
2.66
3.94
2.06
3.05
4.51
2.44
3.60
5.33
2.62
3.87
5.73

35%
SOLIDS
1.32
1.52
1.94
2.13
2.37
2.44
2.73
3.10
3.34
3.65
3.96
4.43
4.54
5.47
5.59
5.82
6.68
7.88
8.47

45%
SOLIDS
1.96
2.25
2.87
3.16
3.51
3.61
4.03
4.60
4.95
5.40
5.86
6.56
6.73
8.10
8.38
8.63
9.89
11.68
12.56

50%
SOLIDS
2.43
2.78
3.56
3.91
4.35
4.47
5.00
5.69
6.12
6.69
7.26
8.13
8.35
10.04
10.39
10.69
12.26
14.47
15.56

TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.17
0.25
0.37
0.19
0.29
0.42
0.25
0.37
0.54
0.27
0.40
0.59
0.30
0.45
0.66
0.31
0.46
0.68
0.35
0.51
0.76
0.40
0.59
0.87
0.43
0.63
0.93
0.46
0.69
1.02
0.50
0.75
1.10
0.57
0.84
1.24
0.58
0.86
1.27
0.70
1.03
1.53
0.74
1.08
1.58
0.74
1.10
1.62
0.85
1.26
1.86
1.01
1.49
2.20
1.08
1.60
2.36

35%
SOLIDS
0.55
0.63
0.80
0.88
0.98
1.01
1.12
1.28
1.38
1.50
1.63
1.83
1.87
2.26
2.31
2.40
2.75
3.25
3.50

45%
SOLIDS
0.81
0.93
1.19
1.30
1.45
1.49
1.66
1.90
2.04
2.23
2.42
2.71
2.78
3.34
3.46
3.56
4.08
4.82
5.18

50%
SOLIDS
1.00
1.15
1.47
1.61
1.79
1.85
2.06
2.35
2.53
2.76
2.99
3.35
3.44
4.14
4.28
4.41
5.06
5.97
6.42

DIRECT GRAVURE
BACKING; LINESPEED
Undercut Required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 90% to 110% LINESPEED

USUALLY REQUIRES POST SMOOTHING

REVERSE GRAVURE

BACKING; LINESPEED
Undercut required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 50% to 150% OF LINESPEED

OFFSET GRAVURE
BACKING; LINESPEED
BACKING/OFFSET =3/8 NIP
OFFSET; 95% to 105% OF LINESPEED
Undercut Required
OFFSET/GRAVURE = 3/8 NIP
GRAVURE; 10% to 25% OF LINESPEED

SMOOTH ROLL

BACKING; LINESPEED
NO Undercut Required
BACKING/PICKUP = VARY NIP
PICKUP;20% to 150% LINESPEED

COAT WEIGHT
NIP WIDTH & ROLL SPEED
Coat weight control is dependent upon the relationship of
linespeed vs. nip width and pickup roll speed
By increasing pickup roll speed the coat weight increases
By decreasing the pickup roll footprint the coat weight
increases
Other coat weight variables
coating solids
coating viscosity
Roll vs. Speed

3/8" nip

Coatweight

1/2" nip

3/4" nip

Roll spee d

Transfer Roll Coater

CHECKING NIP
IMPRESSIONS
RUBBER
COVERED
ROLL
FOOTPRINT

LOAD

STEEL ROLL

Coat Weight Curves

Reverse
Gravure

Forward
Gravure

Offset
Gravure

Smooth
Transfer

100%

150%

GSM

50%

Gravure Speed

GSM

GSM

GSM

95%

100%

105%

10%

Gravure Speed

60%

10%

100%

Gravure Speed

100%

Pick-up Speed

Factors That Affect Coat Weight

Gravure Volume
Roll Speed
Coating Solids
Coating Viscosity
Nip Width

COAT WEIGHT STABILITY

Effects of speed on coatweight
Differential Offset Gravure - STABLE
Direct/Reverse Gravure - STABLE
Smooth Roll - UNSTABLE

Gravure
GSM

Smooth Roll

Line Speed

Coater
Selection

Direct
Gravure

Reverse
Gravure

Offset
Gravure

Smooth
Roll

No

Yes

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

No

Ability to Coat
Printed Film

Yes

No

Yes

Yes

Ability to Coat Foil

Yes

No

Yes

Yes

Ability to Adjust
Coat Weight
Ability to Coat
Paper

Ability to Coat
Film

Stable at All Line

Speeds

Requires Undercut
Rubber Roll

Thank You
PRESENTED BY

Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery
ostnessl@bc-egan.com

Please remember to turn

in your evaluation sheet...